Hello:

I started going over my recently acquired 2005 S40 and noticed that the rear brake pedal was very high, higher than what you see in pictures of the bike and awkward to use.  There is an adjustment bolt with a jam nut to stop the upward movement.  The adjustment bolt is threaded into a lug that is welded on at an angle.  The problem is that the angle is so great that the bolt misses the back of the brake pedal and can't adjust anything.  Someone had bent the bolt and in the right spot it just catches the corner of the pedal so I had to settle with that.

I thought the lug must have been accidentally bent but I looked on Ebay where a couple of those plates are for sale and the pictures show that the lug is at an angle on both of them and the bolt is even bent just like mine.  It looks to me like the factory welding jig is off and holds it at too much of an angle and then when they assemble it they just whack the bolt over a little bit to keep the pedal at the right height.  Is it me, my bike, or does anyone else have this misalignment?

Thanks for looking.  If I bend it perpendiculr to the plate it would be right on.  Maybe that is why the ones on Ebay are for sale, they are also bent.  That is a vulnerable spot down there.  That lug looks fairly tough so I'll probably have to take the plate, pedal etc off and bend it back with a hammer.  I might try a big Crescent wrench first.  Thanks